Vehicle suspension module

ABSTRACT

A suspension module for the suspension systems of vehicles, which is easily removed and replaced in a repair mode. The suspension module comprises a suspension module, a bearing housed in the suspension module wherein the bearing is comprised of a spherical bearing in a housing, the spherical bearing being fixed in the suspension module housing by a crimp in the housing. There is a set of two adapter tubes and a retainer ring mounted on the distal end of the suspension module housing to retain the suspension module in a suspension knuckle of a vehicle suspension system. There is also disclosed a crimping tool for placing a crimp in the housing to retain the spherical bearing therein.

This application claims priority from U.S. Utility Ser. No. 12/322,267filed Jan. 30, 2009.

The invention disclosed herein deals with a new and novel suspensionmodule for the suspension systems of vehicles, which is easily removedand replaced in a repair mode. It also deals with a specialized crimpingtool for fixing a component of the vehicle suspension module in themodule.

BACKGROUND OF THE INVENTION

Spherical bearings are known in the art, for example, In U.S. Pat. No.7,172,352, that issued to Close, et al on Feb. 6, 2007 there is shown aspherical bearing which is a bearing comprising a cylindrical bearingsurface supporting a spherical journal surface.

In U.S. Pat. No. 5,061,087 there is disclosed a bearing apparatus forpermitting axial rotational and angular movement of a doctor journal fora papermaking machine.

A slide bearing unit is described in U.S. Pat. No. 4,910,788 that issuedon Mar. 20, 1990 to Shimizu which is a bearing in which a cylindricalouter cylinder is disposed on the outer periphery of an oil-impregnatedbearing.

In U.S. Pat. No. 4,474,810 a self-aligning idler that is belt driven isfixed with a spherical bearing.

Another such spherical bearing can be found in U.S. Pat. No. 4,355,250that issued on Oct. 19, 1982 to Langdon which is self-aligning.

In still another U.S. Pat. No. 4,251,122 that issued on Feb. 17, 1981 toMcCloskey shows another self adjusting bearing assembly that uses aspherical bearing.

Rod end bearings comprising spherical bearings are disclosed in U.S.Pat. No. 2,804,679 to Tracy.

Bearings similar to those described in the prior art just above can alsobe found in U.S. Pat. No. 5,660,482 that issued on Aug. 26, 1997 toNewley, et al.; Fish, in U.S. Pat. No. 6,860,638; U.S. Pat. No.5,265,965 that issued on Nov. 30, 1993 to Harris, et al; U.S. Pat. No.6,325,544 that issued to Sasaki, et al.; U.S. Pat. No. 7,306,374 thatissued on Dec. 11, 2007 to Hokkirigawa et al; U.S. Pat. No. 6,974,258that issued on Dec. 13, 2005 to Borcherdling, et al; U.S. Pat. No.5,775,815 that issued on Jul. 7, 1998 to Abusamra, and U.S. Pat. No.5,073,038, that issued on Dec. 17, 1991 to O'Connell, among others.

The majority of the prior art dealing with crimping and swaging devicesthat was found by the applicant herein deals with hand held crimping andswaging devices useful for fixing compression sleeves or connectorapparatus on pipes and hoses.

Such a device, for example is that disclosed by Burnett, in U.S. Pat.No. 6,269,675 that issued on Aug. 7, 2001 in which there arecontrollable jaws mounted such that they can be adjusted and operated byhuman hand activity.

In U.S. Pat. No. 7,383,714, that issued to Dimilia, et al on Jun. 10,2008 there is disclosed a crimping machine that includes a linear moverthat forces a ram plate assembly toward a base plate to radiallycontract an insert. The insert has an inner surface defining an interiordimension that mates with a fitting and crushes the fitting onto aflexible hose as the insert is radially contracted. The inserts areessentially flat plates that interface with the entire outside surfaceof the fitting such that the fitting is essentially crushed onto thepipe or hose that is being modified.

THE INVENTION

Thus, this invention deals with a new and novel vehicle suspensionmodule for a vehicle suspension system, said suspension module having incombination a suspension module housing having a distal end and a nearend.

A bearing housed in the suspension module housing, the bearing comprisedof a bearing housing and a spherical bearing wherein the sphericalbearing has a central opening, a first end, and a second end.

The spherical bearing rests against a machined stop at the second endand internally of the housing and the spherical bearing is fixed in thesuspension module housing near the near end of the suspension modulehousing by a crimp in the housing.

There is a set of two adapter tubes, one adapter tube located in thefirst end and partially inserted in the central opening and the otheradapter tube is located in the second end and partially inserted in thecentral opening such that the adapter tubes align with each other.

There is a retainer ring mounted on the distal end of the suspensionmodule housing to retain the suspension module in a suspension knuckleof a vehicle suspension system.

In another embodiment, the suspension module is equipped with seals thatfit over the adapter tubes to prevent the entry of dust and debris.

In yet another embodiment, there is a suspension module as set forthjust Supra wherein, in addition, there is a single rod inserted throughthe seals, the adapter tubes, the housing, and the spherical bearing tosupport these components and align them with each other.

In a third embodiment there is in combination, the suspension module asset forth just Supra, a suspension knuckle of a vehicle suspensionsystem, and an upper control arm of a vehicle suspension system.

The suspension module is fitted and surrounded by a suspension knucklehousing integral within a suspension knuckle and the suspension knucklehousing is joined, by the rod, to an upper control arm through two lowercontrol arm extensions, one control arm extension on either side of thesuspension knuckle housing.

Turning now to another embodiment of this invention, there is amechanical crimping device comprising in combination a cup holder and acrimping cup.

The cup holder has a centered opening therethrough, the centered openinghaving a vertical axis and an inside wall, wherein the top of thecentered opening is larger in diameter than the bottom centered openingto create in the inside wall, a beveled surface.

There is a crimping cup comprised of two identical halves having anoutside wall surface, an inside wall surface, a top and a bottom,wherein the inside wall surface forms a vertical wall parallel to thevertical axis.

The outside wall surface forms a beveled wall wherein the top of thecrimping cup is larger in diameter than the bottom of the crimping cup.

There is a lip formed at the top and on the inside surface of thecrimping cup and a circumferential channel in the outside surface of thecrimping cup, near the bottom thereof, and retained in the channel, anelastomeric ring to hold the two identical halves together. The lip ischamfered where the two identical halves interface with each other.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a full side view of a suspension module of this invention.

FIG. 2 is a cross sectional view of the device of FIG. 1 slightlyreduced in size from FIG. 1 through line A-A.

FIG. 3 is an exploded view in perspective of an upper control arm of avehicle suspension system, in combination with a suspension knuckle of avehicle suspension system and a suspension module of this inventionwithout the rod being in place.

FIG. 4 is a full side view of a crimping tool of this invention.

FIG. 5 is full top view of the cup holder of this invention.

FIG. 6 is a full bottom view of the cup holder of this invention.

FIG. 7 is a full side view of a crimping cup of this invention that isopen.

FIG. 8 is a full side view of a crimping cup of this invention that isentirely closed showing an elastomeric retainer ring.

FIG. 9 is a cross sectional view of a crimping tool of this inventiontaken through line B-B of FIG. 4.

FIG. 10 is a full side view of a crimping tool of this invention showingin phantom, the beveled wall of the cup holder, the beveled wall of thecrimping cup, the elastomeric retainer ring on the crimping cup, thevertical inside wall of the crimping cup, a spherical bearing and ahousing of a suspension module.

FIG. 11 is a full side view of another embodiment of a suspension moduleof this invention.

FIG. 12 is a cross sectional view of the device of FIG. 11 slightlyreduced in size from FIG. 1, through line B-B.

DETAILED DESCRIPTION OF THE DRAWINGS AND INVENTION

Turning now to the description of the invention and with regard to FIG.1, there is shown a full side view of a suspension module 1 of thisinvention. Shown is the suspension module housing 2, the distal end 11of the suspension module housing 2, the near end 3 of the suspensionmodule 1 and the retainer ring 4 used to retain the suspension module 1in the suspension knuckle 5. (shown in FIG. 3).

FIG. 2 is a cross sectional view of the device of FIG. 1, through lineA-A of FIG. 1. It should be noted that the suspension modules of thisinvention can be fabricated from metals or plastics depending on thevehicle that the device needs to be used in. The devices must be capableof carrying the load when they are employed in a suspension system of anautomobile suspension system. Metals for example, are aluminum, steel,iron, brass, bronze, and the like. Preferred is aluminum because of theease by which it can be crimped.

Plastics can be, for example, polyethylene, polypropylene,polyurethanes, polyepoxides, polyesters, cross linked polyethylene andthe like. Preferred for this invention is the cross linked polyethylene.

Therein is shown the housing 2, the bearing 15, comprised of a bearinghousing 16 and a spherical bearing 17. The spherical bearing 17 has anopening 21 through the center to accommodate the insertion of theadapter tubes 14 and 14′ and rod 12 in through the adapter tubes 14 and14′. The rod 12 is shown in phantom in this Figure.

In addition, there is shown the retainer ring channel 18 and the crimps19. The retainer ring 4 when inserted in the retainer ring channel 18prevents the suspension module 1 from backing out of the knuckle housing7 and the crimp 19 and the machined stop 20 secure the spherical bearing17 within the suspension module housing 2.

There are two adapter tubes 14 and 14′ that are insertable in each end(the first end 22 and the second end 23) of the centered opening 21 inthe spherical bearing 17. The adapter tubes 14 and 14′ are essentiallyidentical and are machined at a near end 24 and 24′ to fit in thecentered opening 21 and at the same time, create a machined shoulderthat prevents the adapter tubes 14 and 14′ from entering all the wayinto the centered opening 21. In FIG. 2, the centered opening 21 isexaggerated to show it herein, but in actual use, the adapter tubes 14and 14′ have a machine fit inside of the centered opening 21.

The near end 3 of the suspension module housing 2 has a bell hub 26machined therein to prevent the suspension module housing 2 from movingcompletely through the suspension knuckle housing 7 by virtue of theshoulder 27 created in the suspension module housing 2.

FIG. 3 is an exploded view in perspective of an upper control arm 6 of avehicle suspension system, a portion of which is shown herein. There isalso shown a suspension knuckle 5 of the vehicle suspension systemhaving an integral housing 7 at the top 8 thereof. This integral housing7 is where the suspension module 1 of this invention is used.

Situated just above the suspension knuckle 5 in FIG. 3 is a portion ofan upper control arm 6 of a vehicle suspension system, said uppercontrol arm 6 having two upper extensions 9 and 9′ and two lowerextensions 10 and 10′.

The suspension module 1 of this invention is assembled and placed in thehousing 7 of the suspension knuckle 5. Thereafter, a rod 12(shown inFIGS. 1 and in phantom in FIG. 2) is inserted into the suspension module1 and it moves through a debris seal 13, an adapter tube 14, thespherical bearing 11 (and of course the middle of the housing), throughanother adapter tube 15 and another debris seal 16. The retainer ring 4prevents the suspension module 1 from passing out of the suspensionknuckle housing 5.

The two lower extension arms 10 and 10′ of the upper control arm 6 areplaced alongside the suspension knuckle housing 7 before the rod 12 isplaced into the components. This rod 12 aligns all of the internalcomponents in the suspension module 1 and allows the upper control arm 6to be attached to the suspension knuckle 5 by moving the rod throughopenings 28 and 28′ in the lower control arms 10 and 10′.

When the suspension module 1 is worn and needs to be replaced, the aboveoutlined process is reversed and the old suspension module 1 is replacedby a new suspension module 1 by withdrawing the rod 12, moving the lowercontrol arms 10 and 10′ and removing the retainer ring 4.

Turning now to a detailed description of the crimping tool of thisinvention, and with regard to FIG. 4, there is shown a full side view ofa crimping tool 30 of this invention.

Therein is shown the cup holder 29 containing therein the crimping cup40. The illustration in FIG. 4 shows the general relationship of thecomponents 29 and 40 prior to pressing them together.

FIG. 5 shows a full top view of the cup holder 29 showing the larger(larger than the centered bottom opening 31) centered opening 32 andFIG. 6 shows a full top view of the bottom of the cup holder 29 and thecentered opening 31.

FIG. 7 is a full side view of the crimping cup 40 in an open position.Shown therein is the two identical halves 33 and 33′, the protruding lip34, shown in phantom, and the retainer ring channel 18.

In turn, FIG. 8 shows the same identical halves 33 and 33′ in a closedposition along with an elastomeric retainer ring 4. The elastomericnature of the elastomeric retainer ring 4 is such that it should holdthe two identical halves 33 and 33′ together as shown in FIG. 7 butallow the two identical halves 33 and 33′ to be separated to the extentthat the interior wall 34 of the cup holder 29 will allow for insertionof a suspension module housing 2.

Turning now to FIG. 9, which is a cross sectional side view of thecrimping tool 30 taken through line B-B of FIG. 4, there is shown thecup holder 29, the crimping cup 40, in a fully compressed mode. Itshould be noted that the beveled wall surface of the interior wall 35 ofthe cup holder 29 is beveled as is the exterior wall 36 of the crimpingtool 40 such that the two walls mate and interface with each other.

Also shown in FIG. 9 is the retainer ring channel 18 and the lip 34, thelip 34 having chamfered portion 37 where the two identical halves 33 and33′ interface.

This separation is occasioned by the use of the crimping tool 30. Suchuse is as follows. A suspension module housing 2, containing a bearing15 therein, with the bearing 15 positioned firmly up against themachined stop 20, is placed inside the crimping cup 40 and pushed downuntil the bell housing 26 meets and interfaces with the top 39 of thecrimping cup 40. Thereafter, the crimping tool 40 is placed into thecentered opening 32 through the top of the cup holder 29. This leavesthe crimping cup 40 extended a short distance out of the top opening 32.

Thereafter, the entire assembly is placed in a device that will allowvertical pressure on the suspension module housing 2 which in turnplaces pressure on the bottom of the crimping cup 40 which, because ofthe interface of the beveled walls 35 and 36, causes the bottom of thetwo identical halves 33 and 33′ to come together around the suspensionmodule housing 2, which causes the top of the two identical halves 33and 33′ to come up against the outside wall 41 of the suspension modulehousing 2 wherein the leading edge of the lip 34 presses up against theoutside wall 41 of the suspension module housing 2 and pushes a smallportion of the wall into the space within the suspension module housing2, in a location just above the top or first end 22 of the sphericalbearing 17 (see FIG. 1 at 19). This motion thus crimps the metal of thesuspension module housing 2 over the bearing housing 16 to fix thebearing 15 in place within the suspension module housing 2.

In FIG. 10, there is shown a suspension module housing 2, the crimpingcup 40, wherein the top of the crimping cup 40 extends a slight distanceabove the top of the cup holder 29 while the remainder of the suspensionmodule housing 2 is showing in phantom at 38 along with phantomillustrations of the bevel wall 35 the beveled wall 36, a bearing 15,the retainer ring 4, the machined stop 20, wherein the lip 34 isexaggerated to provide clarification to the Figure.

The device of this invention provides a very slight crimp in the wall ofthe suspension module housing 2. The reason for this controlled crimpingis that it takes very little to hold the bearing in place within thesuspension module housing 2 and if the crimp is taken to excessively, ittends to weaken the wall of the suspension module housing 2 to theextent that it will break in service. Thus, the device of this inventionprovides just the right amount of crimping to hold the bearing 15 withinthe suspension module housing 2 without weakening the wall of thesuspension module housing 2. Crushing the wall of the suspension modulehousing 2 should be avoided at all costs.

Shown in FIG. 11 is another embodiment of this invention which is asuspension module 42 that does not use a crimping system to hold thebearing 15 within the suspension module housing 2.

This embodiment of the invention deals with the use of a snap ring 43 tohold the bearing 15 in the suspension module housing 2 as shown in FIG.12. The snap ring 43 is inserted into a snap ring groove 44 that ismachined into the internal surface of the suspension module housing 2.

1. A vehicle suspension module for a vehicle suspension system, saidsuspension module having in combination: (I) a suspension module housinghaving a distal end and a near end; (II) a bearing housed in thesuspension module housing, said bearing comprised of a bearing housingand a spherical bearing said spherical bearing having a central opening,a first end, and a second end, said spherical bearing resting against amachined stop at the second end and internally of the housing, saidspherical bearing being fixed in the suspension module housing near thenear end of the suspension module housing by a crimp in the housing;(III) a set of two adapter tubes, one adapter tube located in the firstend and partially inserted in the central opening and the other adaptertube located in the second end and partially inserted in the centralopening such that the adapter tubes align with each other, and, (IV) aretainer ring mounted on the distal end of the suspension module housingto retain the suspension module in a suspension knuckle of a vehiclesuspension system.
 2. The vehicle suspension module as claimed in claim1 wherein, in addition, there is a set of two seals, one each mounted oneach of the adapter tubes to prevent the entry of debris.
 3. Thesuspension module as claimed in claim 2 wherein, in addition, there is asingle rod inserted through the seals, the adapter tubes, the suspensionmodule housing, and the spherical bearing.
 4. In combination, a. thesuspension module of claim 3; b. a suspension knuckle of a vehiclesuspension system, c. and an upper control arm of a vehicle suspensionsystem, wherein the suspension module is fitted and surrounded by asuspension knuckle housing integral within a suspension knuckle andwherein said suspension knuckle housing is joined, by the rod, to anupper control arm through two lower control arm extensions, one controlarm extension on either side of the suspension knuckle housing.
 5. Amechanical crimping device comprising in combination a cup holder and acrimping cup: a. wherein the cup holder has a centered openingtherethrough; said centered opening having a vertical axis and an insidewall, wherein the top of the centered opening is larger in diameter thanthe bottom centered opening to create in the inside wall, a beveledsurface; b. the crimping cup comprised of two identical halves having anoutside wall surface, an inside wall surface, a top and a bottom,wherein the inside wall surface forms a vertical wall parallel to thevertical axis; the outside wall surface forming a beveled wall whereinthe top of the crimping cup is larger in diameter than the bottom of thecrimping cup; c. there being a lip formed at the top and on the insidesurface of the crimping cup; d. there being a circumferential channel inthe outside surface of the crimping cup, near the bottom thereof, andretained in the channel, e. an elastomeric ring to hold the twoidentical halves together; the lip being chamfered where the twoidentical halves interface with each other.
 6. A vehicle suspensionmodule for a vehicle suspension system, said suspension module having incombination: (I) a suspension module housing having a distal end and anear end; (II) a bearing housed in the suspension module housing, saidbearing comprised of a bearing housing and a spherical bearing, saidspherical bearing having a central opening, a first end, and a secondend, said spherical bearing resting against a machined stop at thesecond end and internally of the housing, said spherical bearing beingfixed in the suspension module housing near the near end of thesuspension module housing by a snap ring inserted in a snap ring grooveon an internal surface of the housing; (III) a set of two adapter tubes,one adapter tube located in the first end and partially inserted in thecentral opening and the other adapter tube located in the second end andpartially inserted in the central opening such that the adapter tubesalign with each other, and, (IV) a second retainer ring mounted on thedistal end of the suspension module housing to retain the suspensionmodule in a suspension knuckle of a vehicle suspension system.
 7. Thevehicle suspension module as claimed in claim 6 wherein, in addition,there is a set of two seals, one each mounted on each of the adaptertubes to prevent the entry of debris.
 8. The suspension module asclaimed in claim 6 wherein, in addition, there is a single rod insertedthrough the seals, the adapter tubes, the suspension module housing, andthe spherical bearing.
 9. In combination, a. the suspension module ofclaim 6, b. a suspension knuckle of a vehicle suspension system, c. andan upper control arm of a vehicle suspension system, wherein thesuspension module is fitted and surrounded by a suspension knucklehousing integral within a suspension knuckle and wherein said suspensionknuckle housing is joined, by the rod, to an upper control arm throughtwo lower control arm extensions, one control arm extension on eitherside of the suspension knuckle housing.